Method of monitoring wear in a diaphragm valve using pressure detection

ABSTRACT

A system for detecting wear in a flush valve includes at least one pressure sensor adapted to measure a water pressure within the flush valve and at least one microprocessor in communication with the at least one pressure sensor. The at least one microprocessor is configured to determine the water pressure within the flush valve measured by the at least one pressure sensor at or after a predetermined time following operation of the flush valve that is equal to or exceeding a known time required to reseal the flush valve during normal operation, compare the determined water pressure with a pressure value sufficient to reseal the flush valve during normal operation, and determine if the flush valve is worn based at least partially on the comparison. A method and apparatus is also disclosed.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.14/199,376, filed Mar. 6, 2014, which is a divisional of U.S. patentapplication Ser. No. 12/776,746, filed May 10, 2010, which is adivisional of U.S. patent application Ser. No. 11/246,332, filed Oct. 7,2005, now U.S. Pat. No. 7,735,513, which claims the benefit of U.S.Provisional Application Ser. No. 60/617,264, filed Oct. 8, 2004, theentire disclosures of each of which are hereby incorporated herein byreference in their entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates generally to diaphragm valves and, in oneparticular embodiment, to a plastic body diaphragm valve having apressure relief for use as a flush valve in a waste water system.

2. Technical Considerations

In most waste water systems, such as the flushing systems for urinals,commodes, and the like, the valves associated with these systems aretraditionally metal valves. Metal valves provide strength forwithstanding high-pressure fluctuations that may occur in the waterpressure of the flushing system and also maintain their ability tofunction over prolonged and consistent use. However, these traditionalmetal flush valves do have some drawbacks. For example, these metalvalves are typically relatively heavy and cumbersome to install andrepair. Moreover, with continued use, metal valves may corrode or rust,and/or develop mineral deposits, which can require replacement of theentire valve. Additionally, such metal valves are typically expensive tomanufacture and maintain.

Plastic valves are generally lighter in weight and less costly thanmetal valves and eliminate the corrosion associated with metal valveswhile reducing the development of mineral deposits. However, plasticvalves are typically not as strong as metal valves. That is, plasticvalves cannot typically withstand as high fluid pressures as metalvalves without leaking or breaking. While plastic valves do exist, theseknown plastic valves are not capable of meeting the American Society OfSanitary Engineering (ASSE) requirements for use in conventional wastewater systems. For example, one ASSE requirement is that the valves inthe waste water system must not leak at a fluid pressure of 500 psi or,if the valve incorporates a relief valve, the valve must hold two-timesthe relief pressure without leaking. Conventional plastic bodied valvescannot meet these limitations.

Additionally, many modern commodes and/or urinals are designed tooperate most efficiently using a standard amount of water per flush,typically in the range of 1.5 to 2 gallons per flush. Therefore, knownmetal flush valves are designed to provide a selected amount of waterper flush when new. However, with continued or prolonged use over timeor as the internal components of the metal valve wear, it is notuncommon for these known metal flush valves to provide a differentamount of water per flush than they were originally designed to provide.For example, a metal flush valve originally designed to provide 1.6gallons per flush when new may eventually provide 2 or more gallons perflush due to valve component wear or use. For large applications, suchas hospitals, prisons, apartment buildings, and the like, this can leadto an increase in water usage and cost. Additionally, these known flushvalves cannot compensate for variations in water pressure during theflushing cycle that can also affect the amount of water per flush thevalve provides.

Therefore, it would be advantageous to provide a flush valve thatreduces or eliminates at least some of the problems associated withknown flush valves. For example, it would be advantageous to provide aplastic body flush valve with a relief system that meets current ASSErequirement. It would likewise be advantageous to provide a flush valvethat can provide a predetermined amount of water per flush despite valvewear and/or water pressure fluctuations.

SUMMARY OF THE INVENTION

A flush valve for a waste water system comprises a valve including afluid inlet, a fluid outlet and a main valve element extending betweenthe fluid inlet and the fluid outlet, with the main valve elementadapted for movement to allow fluid flow between the fluid inlet and thefluid outlet based on a pressure differential across a portion of themain valve element. The valve also includes a vent system comprising acontrol chamber in flow communication with the fluid inlet of the valveand a vent outlet in flow communication with the fluid outlet of thevalve. The valve further includes a solenoid including a pistonconfigured to open to establish flow communication between the controlchamber and the vent outlet for venting fluid from the control chamberto the fluid outlet and establishing a pressure differential across aportion of the main valve element to open the main valve element forfluid flow between the fluid inlet and fluid outlet of the valve. Thepiston is also configured to close to prevent fluid communicationbetween the control chamber and the vent outlet to close the main valveelement. The valve also comprises a pressure sensor, such as anelectronic pressure transducer, adapted to sense the fluid pressure offluid within the vent system. The pressure sensor can regulate theinternal pressure within the valve to prevent leakage and/or damage ofthe valve based on excessive pressure therein, and is thereforeparticularly useful with valves where least a portion of the valve bodyis constructed of a plastic material.

The vent system may include a vent chamber in flow communication withthe control chamber through a vent inlet passage extending between thecontrol chamber and the vent chamber, with the vent outlet is in flowcommunication with the vent chamber. Moreover, the solenoid may includea core tube in which the piston is slidable, with the core tube in flowcommunication with the vent chamber, and with an actuating coil aroundat least a portion of the core tube. In such an embodiment, the pressuresensor can extend into the core tube.

A method of controlling a flush valve comprises provided such as flushvalve, defining a pressure threshold corresponding to a relief pressurefor the valve, sensing the fluid pressure of fluid within the valve, andactivating the solenoid when the fluid pressure within the valve meetsor exceeds the defined pressure threshold.

In a further embodiment, a method of regulating pressure within a flushvalve in a waste water system comprises providing a valve including afluid inlet, a fluid outlet and a main valve element adapted formovement to allow fluid flow between the fluid inlet and the fluidoutlet based on a pressure differential across a portion of the mainvalve element. The valve further comprises a vent system for ventingfluid from the fluid inlet to the fluid outlet to establish a pressuredifferential across a portion of the main valve element to cause themain valve element to open. In the method, the fluid pressure of fluidwithin the vent system of the valve is sensed. Fluid within the ventsystem of the valve is vented from the fluid inlet to the fluid outletwhen the fluid pressure within the vent system exceeds a predeterminedpressure threshold corresponding to a relief pressure for the valve.

Desirably, the vent system comprises a control chamber in flowcommunication with the fluid inlet of the valve, a vent outlet in flowcommunication with the fluid outlet of the valve, and an electronicallyoperated solenoid having a piston configured to open and close the ventoutlet upon energization thereof. In such an embodiment, the ventingstep comprises energizing the solenoid to open the vent outlet toestablish flow communication between the control chamber and the ventoutlet to vent fluid from the control chamber to the fluid outlet. Thesolenoid may be energized for a predetermined period of time. Desirably,the solenoid is energized for a period of time below that required tovent a volume of fluid from the vent chamber associated withestablishing a pressure differential across a portion of the main valveelement which would cause the main valve element to open. In thismanner, the fluid pressure within the vent chamber can be reduced belowa threshold level without opening the main valve element.

A voltage threshold may further be defined, corresponding to thepredetermined pressure threshold for the valve. In this manner, thesolenoid can be energized when the voltage threshold is detected.Moreover, a closing voltage threshold corresponding to a pressure valuebelow the predetermined pressure threshold for the valve may also bedefined. As such, the solenoid can be de-energized when the closingvoltage threshold is attained.

In a further embodiment, a method of operating a flush valve in a wastewater system comprises providing a valve including a fluid inlet, afluid outlet and a main valve element adapted for movement to allowfluid flow between the fluid inlet and the fluid outlet based on apressure differential across a portion of the main valve element. Thevalve comprises a vent system for venting fluid from the fluid inlet tothe fluid outlet to establish a pressure differential across a portionof the main valve element to cause the main valve element to open, withthe vent system comprising a control chamber in flow communication withthe fluid inlet of the valve, a vent outlet in flow communication withthe fluid outlet of the valve, and an electronically operated solenoid.The solenoid includes a piston configured to open the vent outlet uponenergization thereof to establish flow communication between the controlchamber and the vent outlet to vent fluid from the control chamber tothe fluid outlet, and to close the vent outlet upon de-energizationthereof. Operation of the valve involves sensing the static fluidpressure of fluid within the vent system, calculating a valve operationtime associated with delivering a predetermined quantity of waterthrough the valve based on the static fluid pressure, and energizing thesolenoid for a time period associated with the valve operation time.Desirably, the predetermined quantity of water is 1.6 gallons, therebyeffecting flushing of a toilet fixture associated with the valve.

The method may further comprise monitoring the dynamic fluid pressure offluid within the vent system during the valve operation, and adjustingthe time period of energization of the solenoid based on the dynamicfluid pressure to regulate the valve operation time.

BRIEF DESCRIPTION OF THE DRAWINGS

Additional advantages and details of the invention are explained ingreater detail below with reference to the exemplary embodiments thatare illustrated in the accompanying schematic figures, in which:

FIG. 1 is a side view of a plastic bodied valve incorporating featuresof the invention;

FIG. 2 is a top view of the valve of FIG. 1;

FIG. 3 is an exploded view of the valve of FIG. 1;

FIG. 4 is a side, sectional view of the valve of FIG. 1 in a closedconfiguration;

FIG. 5 is a side, sectional view of the valve of FIG. 1 in an openconfiguration;

FIG. 6 is a side, cut-away view of a portion of a valve incorporating avalve relief system of the invention;

FIGS. 7-9 are side, cut-away views of valve portions similar to FIG. 3but incorporating alternative valve relief systems;

FIG. 10 is a side, sectional view of a valve of the invention having avalve relief system located in the valve body;

FIG. 11 is a side, cut-away view (not to scale) of an alternative valverelief system of the invention;

FIG. 12 is a side, cut-away view (not to scale) of another valve systemincorporating features of the invention; and

FIG. 13 is a side, cut-away view (not to scale) of a further valvesystem of the invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

As used herein, spatial or directional terms, such as “up”, “down”,“above”, “below”, “top”, “bottom”, and the like, relate to the inventionas it is shown in the drawing figures. However, it is to be understoodthat the invention can assume various alternative orientations and,accordingly, such terms are not to be considered as limiting. Further,all numbers expressing dimensions, physical characteristics, processingparameters, quantities of ingredients, reaction conditions, and thelike, used in the specification and claims are to be understood as beingmodified in all instances by the term “about”. Accordingly, unlessindicated to the contrary, the numerical values set forth in thefollowing specification and claims are approximations that can varydepending upon the desired properties sought to be obtained by thepresent invention. At the very least, and not as an attempt to limit theapplication of the doctrine of equivalents to the scope of the claims,each numerical value should at least be construed in light of the numberof reported significant digits and by applying ordinary roundingtechniques. Moreover, all ranges disclosed herein are to be understoodto encompass any and all subranges subsumed therein. For example, astated range of “1 to 10” should be considered to include any and allsubranges between (and inclusive of) the minimum value of 1 and themaximum value of 10; that is, all subranges beginning with a minimumvalue of 1 or more and ending with a maximum value of 10 or less, e.g.,1 to 6.1, 3.5 to 7.8, 5.5 to 10, etc. All references referred to herein,such as but not limited to issued patents and published applications,are to be understood to be incorporated by reference in their entirety.The term “mechanical relief” refers to a relief device or system thatdoes not require electricity or electrical power to function in apressure relieving capacity. The term “electronic relief” refers to arelief device or system that utilizes electricity or electrical power tofunction in a pressure relieving capacity.

FIGS. 1-5 show a valve 10 of the present invention. The basic componentsof the valve 10 will first be described in order to clarify thesubsequent discussion of the invention.

In one non-limiting embodiment, the valve 10 can be a diaphragm-typevalve having a valve housing 12 formed by a valve body 14 and a cover16. The valve body 14 and/or cover 16 can be of any desired material,for example, metal or plastic. In one non-limiting embodiment, the valvebody 14 and cover 16 can both be made of plastic or one can be plasticand the other metal. The valve body 14 has a flow passage extendingtherethrough with an inlet end 18 and an outlet end 20. The cover 16 isconnected to the valve body 14 by a plurality of bolts 22, such asaluminum or stainless steel bolts, threadably engagable with insert nuts24 in the valve body 14. The insert nuts 24 can also be metal, such asbrass or, more preferably, steel. A diaphragm 26 of suitable material,such as rubber or plastic, is sandwiched between the valve body 14 andthe cover 16 to form a seal between the two chambers of the valve 10. Avalve element 300 is positioned in the flow passage and the upper sideof the valve element 300 engages the central region of the diaphragm 26when the valve 10 is assembled. In one embodiment, the valve element 300is a conventional swing check valve. The valve 10 further includes asolenoid 28 threadably attached to the cover 16 and operationallyconnected with a vent system to control water pressure in a controlchamber formed above the diaphragm 26, as is typical in known diaphragmvalves. As will be described in more detail below, in one non-limitingembodiment the vent system includes a passage, such as a crescent-shapedvent passage, in flow communication on one end with the control chamberand on the other end with a vent chamber. Flow through a vent outlet forthe vent chamber is controlled by a plunger 29 associated with thesolenoid 28, which can be moved to open or close the vent outlet. Thevalve 10 also includes a rotatable stop 30 that can be used to adjust orcontrol the maximum opening position of the valve element.

The valve 10 also includes a swing check retaining ring 302 to retainthe valve element 300 in the valve body 14. In the illustratedembodiment, the solenoid 28 is connected to the valve cover 16 by ableed plug or fitting 90. A manual override lever 304 can be operativelyconnected to the solenoid 28.

FIG. 4 shows the valve 10 in a closed configuration in which the valveelement 300 blocks the flow passage, preventing fluid flow through thevalve 10. FIG. 5 shows the valve 10 in an open configuration in whichfluid can flow from the inlet end 18, through the flow passage, and outthe outlet end 20.

The above-described diaphragm valve basic components and their operationwill be well understood by one of ordinary skill in the diaphragm valveart and, hence, will not be described in any great detail. Examples ofknown diaphragm valves and their operation are described, for example,in U.S. Pat. Nos. 4,336,918; 4,301,992; 4,893,645; 4,797,820; 4,477,051;4,787,413; 5,853,026; and 6,557,580. However, unlike conventionaldiaphragm valves, the valve 10 of the invention includes operationalelements and/or a relief system in accordance with the invention, aswill now be described, which make the valve particularly useful as aflush valve in a waste water system.

A portion of the valve 10 of the invention incorporating a mechanicalrelief assembly is shown in FIG. 6. The bleed plug or fitting 90 has afirst end 92 and a second end 94. The first end 92 is connectable withthe valve 10, such as with the cover 16, and the second end 94 engagesthe solenoid 28. In the embodiment illustrated in FIG. 6, the first end92 of the fitting 90 has external threads 96 configured to engagethreads on the cover 16, and the second end 94 has internal threads 98configured to engage threads on the solenoid 28. The valve 10 has a ventsystem incorporating a vent inlet passage 100 with one end (lower end)in flow communication with a control chamber 102 and the other end(upper end) in flow communication with a vent chamber 104. A vent valveseat 106 is located in the vent chamber 104 and is in flow communicationwith a vent outlet conduit 108. When the fitting 90 is engaged with thecover 16, the first end 92 of the fitting 90 contacts a raised sealingmember 107. An outlet conduit 109 in the sealing member 107 aligns withthe lower end of the outlet conduit 108 in the fitting 90.

Flow through the outlet conduit 108 is controlled by a piston 110 of thesolenoid 28. The piston 110 is slidable within a core tube 111surrounded by a coil 113, as is conventional in many solenoids. As shownin FIG. 6, when the piston 110 is engaged with the vent valve seat 106,flow to the vent outlet conduit 108 is prevented. The fluid pressure inthe control chamber 102 is built up to be equal to the fluid pressure ofthe fluid supply source entering valve 10 through inlet end 18. Inparticular, fluid flows into valve 10 through inlet end 18, throughchamber inlet 15 and into control chamber 102 above diaphragm 26.Control chamber 102 extends across the top of valve 10 over diaphragm 26and into the portion of valve 10 to which solenoid 28 is threadedthereto. With the piston 110 of solenoid 28 seated on vent valve seat106, vent chamber 104 is closed from fluid communication across ventvalve seat 106, and control chamber 102 is therefore closed as well. Thefluid pressure within control chamber 102 applies a force acrossdiaphragm 26, maintaining the diaphragm 26 in an extending position andpreventing it from lifting, thereby maintaining the swing check valve300 in a downward state and preventing swing check valve 300 fromlifting, thus preventing fluid flow through the valve 10. When thepiston 110 is retracted (i.e., moved upwardly), such as by energizingthe coil 113, fluid communication is established between vent chamber104 and vent outlet 108, thus opening the vent outlet conduit 108 andallowing fluid flow from the vent inlet passage 100, through the ventchamber 104, and out the vent outlet conduit 108 into the outlet end 20of the valve 10, from where the fluid passes to the fixture associatedwith valve 10. The vent system is used to bleed pressure from thecontrol chamber 102 to open the main valve element in the valve body 14.This allows the valve element to be opened and closed to control fluidflow through the valve 10.

More particularly, as will be appreciated by one of ordinary skill inthe art, the solenoid 28 is connected to a conventional actuator, suchas a conventional push-button actuator, to effect actuation of the valve10 during normal use of the valve 10, such as to effect flushing of anattached fixture. To flush the equipment associated with the valve 10,the actuator is activated. This sends an electrical signal to the coil113 which energizes the coil 113, thereby causing the piston 110 to liftfrom the vent valve seat 106. Such movement opens vent valve seat 106and places vent chamber 104 in fluid communication with vent outlet 108.Thus, fluid flow is established from the control chamber 102, throughthe vent inlet 100, through vent chamber 104, and out the vent outlet108, into the outlet end 20 of the valve 10. This relieves the pressurein the control chamber 102, creating a pressure differential across thediaphragm 26 and the main valve element, i.e. the swing check valve 300,in the flow passage, which is pressurized with fluid pressure from fluidflowing from the main water source attached at inlet end 18 of valve 10.This pressure differential effects movement of the swing check valve300, thereby opening valve 10 for fluid flow between inlet end 18 andoutlet end 20. To close the main valve element, the solenoid 28 isdisengaged (e.g., the coil 113 is de-energized) such that the piston 110re-engages the vent valve seat 106 to close the vent outlet 108. Suchclosure closes off any fluid flow therethrough, thereby allowing fluid,i.e. water, to re-accumulate in vent chamber 104, and re-pressurizingthe control chamber 102 above diaphragm 26 and closing swing check valve300.

Valve 10 of the present invention further incorporates a pressure reliefsystem or assembly in order to prevent the build-up of internal pressurewithin valve 10 beyond a predetermined threshold limit. In particular,valve 10 is designed for use as a flow control valve in water systems,such as a waste water system. Such water systems involve incoming waterflow from a main water system, which may be a city water supply. Assuch, these water systems are subject to fluctuations in water pressure.In order to prevent damage to the internal operations of the valve fromany spikes in water pressure or excessive build up of pressure, valve 10incorporates a pressure relief system.

The pressure relief system may be incorporated into any portion of thevalve 10. In one embodiment, the relief system is incorporated adjacentthe solenoid operation of the valve 10. In particular, in one practiceof the invention, the valve 10 can incorporate a mechanical reliefassembly 112 at fitting 90, as depicted in FIG. 6. In this embodiment, arelief system comprises a relief chamber 114 formed in the fitting 90.This can be done in any conventional manner, such as by drilling ormolding a fitting to have the relief chamber 114. The relief chamber 114includes a relief inlet 116 in flow communication with the controlchamber 102 and a relief outlet 118 in flow communication with the ventoutlet conduit 108. A mechanical relief device, such as a relief valve120, is positioned in the relief chamber 114. The relief valve 120 canbe of any conventional type. However, in the illustrated embodiment, therelief valve 120 is a ball relief valve having a ball 122 biased by aspring 124. The spring 124 can be connected at an end opposite of theball to a plug 126 that can be formed in the fitting 90 or can beengaged with the fitting 90 in any conventional manner. For example, theplug 126 can be configured to engage threads formed in the reliefchamber 114. Alternatively, the upper end of the relief chamber 114 canbe closed, in which case no plug 126 would be required.

The spring 124 is configured such that at fluid pressures below apredefined value, the spring bias pushes the ball 122 against a sealingsurface at the relief inlet 116 opening to close the relief inlet 116.However, if the forces applied against the ball 122 based on the fluidpressure applied against the ball 122 at the relief inlet 116 reaches orexceeds the predefined value (based on the bias of the spring 124), thefluid pressure overcomes the bias of the spring 124 to push the ball 122inwardly to open the relief inlet 116 to prevent fluid flow through therelief assembly 112. As will be appreciated by one skilled in the art,the predefined relief pressure can be changed or adjusted by replacingthe spring 124 with another spring of differing spring bias.

In the practice of the invention, the relief assembly 112 prevents overpressurization of the interior of the valve 10 to prevent leakage and/ordamage to the valve at high pressures. For example, with reference toFIG. 6, should the pressure in the control chamber 102 meet or exceed apredetermined relief pressure based on the bias of the spring 124, theball 122 is pushed away from the inlet 116 against the bias of thespring 124 to allow fluid to flow through the inlet 116 and out therelief outlet 118 into the vent outlet 108. When the fluid pressuredrops below the preset value for the relief valve 120, the bias of thespring 124 forces the ball 122 to close the inlet 116 to stop anyadditional fluid flow through the relief assembly 112.

FIG. 7 shows an alternative configuration of a mechanical reliefassembly 128 of the invention. In this embodiment, the inlet 116 of therelief chamber 114 is in flow communication with the water source fromthe control chamber 102 at the vent chamber 104 rather than directly atthe control chamber 102. However, the relief assembly 128 would work ina similar manner as the relief assembly 112 described above in that whenthe pressure in the vent chamber 104 rises above a pre-selected value,the fluid pressure forces the ball 122 downwardly against the bias ofthe spring to allow fluid to flow out of the relief outlet 118 and intothe vent outlet 108, thereby relieving the pressure against thediaphragm 26 to effect movement of the swing check valve 300, therebyopening valve 10 for fluid flow therethrough and relieving the pressureinside valve 10 to protect from damage or leakage.

FIG. 8 is an alternative embodiment of a mechanical relief assembly 130incorporating features of the invention. In this embodiment, the inlet116 for the relief chamber 114 is in flow communication with the ventinlet passage 100 such that when pressure in the vent inlet passage 100rises above the pre-selected level, the relief valve 120 opens and fluidflows from the vent inlet passage 100 through the relief outlet 118 intothe vent outlet 108.

FIG. 9 is similar to the configuration shown in FIG. 7 but thespring-biased ball relief is replaced with a compressible plug or member150 configured to deform at a pre-selected pressure such that when thepressure in the vent chamber 104 reaches the pre-selected pressure, thepressure deforms the compressible member 150 to open the relief outlet118. In one specific embodiment, the compressible member 150 can be of adurometer selected to provide a selected opening pressure. The materialcan be, for example, neoprene, rubber, or the like.

A further mechanical relief assembly 310 is shown in FIG. 10. In thisembodiment, the relief assembly 310 is formed in a portion of the valvebody 14, such as in the valve element 300, rather than in the solenoid28 as in the embodiments described above. The relief assembly 310comprises a relief chamber 312 formed in the valve element 300 andhaving a relief inlet 314 on the inlet side 316 of the valve element300, i.e., in flow communication with the inlet side of the flowpassage. A relief outlet 318 extends between the relief chamber 312 andan outlet side 320 of the valve element 300, i.e., one end of the reliefoutlet 318 is in flow communication with the relief chamber 312 and theother end of the relief outlet 318 is in flow communication with theoutlet side of the flow passage.

A mechanical relief valve 322 (relief device) of any conventional typeis located in the relief chamber 312. In the illustrated embodiment, themechanical relief valve 322 is depicted as a ball relief valve having aball 122 biased by a spring 124 as described above. The spring 124 isselected or configured such that at fluid pressures on the inlet side316 of the valve element 300 below a predetermined value, the spring 124pushes the ball 122 against a sealing surface at the relief inlet 314 toclose the relief inlet 314. However, if the fluid pressure on the inletside 316 of the valve element 300 reaches or exceeds the predeterminedvalue based on the bias of the spring 124, the fluid pressure overcomesthe bias of the spring 124 to push the ball 122 inwardly to open therelief inlet 314 and allow fluid flow through the relief chamber 312 andout the relief outlet 318. In this manner, the inlet side of the flowpassage is placed in flow communication with the outlet side of the flowpassage through the valve element 300 via the relief assembly 310,thereby venting a portion of fluid, i.e., water, therethrough. Oncesufficient fluid flow through the relief assembly 310 causes the fluidpressure at the inlet side 316 of the valve to be reduced to a valuebelow the predetermined threshold based on the bias of the spring 124,the spring 124 pushes the ball 122 back to the sealing position, closingoff the relief chamber 312 from further fluid flow therethrough. Thisembodiment prevents over-pressurization of the valve 10 based onbleeding small volumes of water through the valve 10, therebyeffectively relieving internal pressure build-up without effecting fullopening of the valve element 300, and therefore without fully flushingany fixture associated with the valve 10.

In a further embodiment of the invention, the pressure relief systemincorporates an electronic mechanism for detecting pressure within thevalve in excess of a predetermined limit, as opposed to (or in additionto) a mechanical mechanism as set forth in the embodiments previouslydescribed. In particular, an electronic pressure relief assembly may beincorporated into a portion of valve 10, so as to effectively measure towater pressure within valve 10, such as within control chamber 102, toprevent a build up of excessive pressure therein. Desirably, such anelectronic pressure relief system may be incorporated into a portion ofthe valve adjacent other electronically operated features of the valve,such as adjacent to or integrated with the solenoid portion of thevalve. In this manner, a conventional valve such as that disclosed inFIG. 1 above or such as disclosed U.S. Pat. No. 4,336,918 can be easilymodified and retrofitted by replacing a conventional solenoid operatorwith a modified solenoid incorporating an electronic relief assembly asdisclosed in the present invention.

For example, a portion of a valve 10 incorporating an electronic reliefassembly 200 in accordance with a further embodiment is shown in FIG.11. In this embodiment, a modified solenoid 202 is utilized. Thesolenoid 202 engages the plug or fitting 90, for example as describedabove with respect to FIG. 6. The solenoid 202 includes a piston 204slidable within a core tube 206. A coil surrounds at least a portion ofthe core tube 206. The coil can be a single coil 113 as described aboveor, in the illustrated embodiment, the coil can comprise a first coilsection 208 and a second coil section 210. The first coil section 208 islocated at or near the bottom or open end 212 of the core tube 206. Thesecond coil section 210 is located at or near the top or closed end 214of the core tube 206.

In this electronic relief assembly 200, a pressure transducer 216 isconnected to the solenoid 202 and is configured to measure the fluidpressure within the valve, e.g., in the vent chamber 104, which is influid communication with the control chamber 102. For example, in oneembodiment the pressure transducer 216 can be configured to extend intothe vent chamber 104. Alternatively, in the embodiment shown in FIG. 11,the pressure transducer 216 can be connected to the top 214 of the coretube 206 and can extend into the interior of the core tube 206. As willbe appreciated by one skilled in the art, a gap exists between theoutside diameter of the piston 204 and the inside diameter of the coretube 206 such that fluid in the vent chamber 104 flows into the coretube 206 around the piston 204. Thus, the pressure in the core tube 206should be substantially the same as that in the vent chamber 104 and thecontrol chamber 102. The pressure transducer 216 is in electroniccommunication with a control board 218 in any conventional manner, suchas by one or more wires or cables 220. The control board 218 can be, forexample, a conventional 410 or 810 control board, as is known to thoseof ordinary skill in the art. The control board 218 is connected to anelectrical power source to provide electrical power to the solenoid 202in any conventional manner, such as by one or more cables 222. Thecontrol board 218 is in electronic communication, such as by a wire orcable 224, with an actuator 226, such as a conventional push button orsimilar actuator.

The relief assembly 200 in the embodiment of FIG. 11 operates as followsin one non-limiting embodiment. The pressure transducer 216 senses thestatic fluid pressure inside the core tube 206. By “static pressure” ismeant the fluid pressure when the solenoid 202 is de-energized, that is,when the piston 204 engages the valve seat 106. The system can beconfigured such that a pressure range sensed by the pressure transducer216 can correspond to an output signal of the transducer 216. Forexample, a pressure range of 0 to 150 psi can correspond to an outputsignal of 0 to 5 volts DC. A high-voltage threshold can bepredetermined, which corresponds to a relief pressure for the reliefassembly 200. By “relief pressure” is meant the fluid pressure at whichthe relief assembly 200 is activated. The static pressure can bemonitored either continuously or intermittently by a microprocessor 228associated with a pressure transducer control 230 on the control board218. Depending upon the output signal of the pressure transducer 216, anamplifier 232 can also be present on the control board 218 to boost theoutput signal from the pressure transducer 216, if needed. In any event,when the high-voltage threshold is detected (i.e., the relief pressureis attained), the microprocessor 228 sends a signal to energize thesolenoid 202.

In one embodiment, the solenoid can be energized for a predeterminedperiod of time, for example, in the range of 1 to 3 seconds. This liftsthe piston 204 off of the valve seat 106 for that predetermined periodof time to open the vent outlet 108 for fluid flow therethrough, therebyreleasing a portion of the fluid within vent chamber 104 and controlchamber 102, and lowering the pressure within the vent chamber 104 andcontrol chamber 102. After this predetermined period of time, thesolenoid 202 is de-energized such that the piston 204 again engages thevalve seat 106. The pressure transducer 216 may thereafter again sensesthe static pressure inside the core tube 206. If the static pressure asmeasured within vent chamber 104 is still above the relief pressure(that is, the output signal of the pressure transducer 216 is at orabove the high-voltage threshold), the microprocessor 228 againactivates the solenoid 202 for a predetermined period of time to liftthe piston 204 to again open the vent outlet 108 for fluid flowtherethrough, relieving at least some of the fluid pressure within thevent chamber 104 and control chamber 102. This cycle can continue untilthe static pressure sensed by the pressure transducer 216 is below thepredetermined relief pressure.

In a further embodiment, operation of the solenoid to relieve thepressure within valve 10 is not necessarily based on a predeterminedtime value for venting a specified volume of fluid out of vent chamber104 and control chamber 102, but is instead based on the internalpressure within valve 10 during the venting as measured by the pressuretransducer 216. For example, when the high-voltage threshold is attained(i.e. the relief pressure is attained based on the measurement from thepressure transducer 216), the solenoid 202 is activated to lift thepiston 204 and relieve the pressure, and the solenoid 202 remainsenergized. In this embodiment, the pressure transducer 216 continues tomonitor the internal fluid pressure within the core tube 111 and/or thevent chamber 104 while the solenoid 202 is energized. The solenoid 202remains energized until the pressure transducer 216 senses a closingvoltage threshold, i.e., a voltage associated with a predefined fluidpressure at which the solenoid 202 is to be de-energized. The closingvoltage threshold corresponds to a voltage output corresponding to adynamic fluid pressure defined as the closing pressure. By “dynamicfluid pressure” is meant the fluid pressure in the core tube 111 and/orvent chamber 104 while the solenoid 202 is energized, that is while thepiston 204 is off of the valve seat 106 and fluid is flowing through thevent chamber 104 and out the vent outlet 108. For example, themicroprocessor 228 may be programmed such that a closing voltagethreshold may correspond to a specific pressure within the vent chamber104, such as a voltage threshold of 3.2V DC corresponding to 100 psi,representing an acceptable internal pressure to prevent damage withinvalve 10. When the dynamic fluid pressure measured by pressuretransducer 216 reaches the acceptable threshold corresponding to theclosing voltage threshold, the microprocessor 228 de-energizes thesolenoid 202 to cause the piston 204 to move downwardly to re-engage thevalve seat 106 and seal off the vent outlet 108.

As will be appreciated by one skilled in the art, the above reliefmethods may allow sufficient fluid flow through out of vent chamber 104and control chamber 102 through vent outlet 108 to cause a sufficientdrop in pressure within control chamber 102 which would releasediaphragm 26, thereby opening the main valve element 300 of valve 10. Assuch, the equipment or fixture associated with the flush valve 10, suchas a commode or urinal, would be caused to flush when the piston 204 islifted from the valve seat 106 to relieve the fluid pressure. Theinvention, however, further provides embodiments which effectivelyrelease the pressure within valve 10 without necessarily dropping thepressure of control chamber 102 below the required threshold to maintaindiaphragm 26 closed, thereby preventing operation of valve 10.

For example, it is contemplated that in a single coil system such asthat described above, the microprocessor may be programmed differentlydepending on whether a normal flush request from actuator 226 isreceived or whether a high voltage threshold is detected based on asignal from the pressure measured by the pressure transducer 216. If theequipment is to be flushed such as based on receipt of a normal flushrequest from actuator 226, the microprocessor 228 sends a signal toenergize the solenoid to lift the piston 204 off of the valve seat 106to open the vent outlet 108 for venting of control chamber 102 for asufficient period of time typically associated with operation of thevalve 10, in order to effect opening of the valve element of the valve10 and to flush the associated fixture or equipment, such as for aperiod of more than 3 seconds. On the other hand, when a high voltagethreshold is detected based readings from the pressure transducer 216,the microprocessor 228 can send a signal to energize the solenoid foronly a limited predetermined period of time below that which is normallyassociated with release of the control chamber 102 which would effectopening of the valve 10, such as a period of less than 1 second. In thismanner, the pressure can be effectively released within valve 10 withouteffecting a full flush of the fixture associated with the valve 10.

Alternatively, the illustrated embodiment of FIG. 11 utilizes a two-partcoil to prevent complete opening of valve 10 to prevent flushing of theassociated equipment. For example, if the equipment is to be flushedsuch as based on receipt of a normal flush request from actuator 226,the upper or second coil section 210 can be energized to lift the piston204 off of the valve seat 106 to open the vent outlet 108 for asufficient period of time typically associated with venting of controlchamber 102 for operation of the valve 10, in order to effect opening ofthe valve element of the valve 10 and to flush the associated fixture orequipment. However, if a pressure above the high-voltage threshold isdetected by the pressure transducer 216, the microprocessor 228activates only the lower coil 208 to slightly lift the piston 204 off ofthe valve seat 106 for a brief period of time, e.g., less than 1 second.If the piston 204 is lifted only for a short period of time and/or islifted only slightly off of the valve seat 106 in order to lower thepressure in the vent chamber 104, flushing of the associated equipmentmay be prevented.

Under normal operation, when the valve 10 is to be opened to permitflushing of an associated component, the actuator 226 is actuated, suchas by pressing a button. Upon receiving the actuation signal, thecontrol board 218 sends a signal via the cable 222 to the solenoid 202to energize the coils (113 or 210) to lift the piston 204 off of thevalve seat 106. This vents the fluid in the vent chamber 104 through thevent outlet 108, thereby venting the control chamber 102 and opening thevalve element 300 of the valve 10. In one practice of the invention,when the actuation signal is received, the microprocessor 228 determinesthe static fluid pressure inside the core tube 206 by the pressuretransducer 216. Based on this sensed static pressure, the microprocessor228 calculates a flush time in order for the valve 10 to deliver adesired quantity of water. The microprocessor 228 actuates the solenoid202 to lift the piston 204 for a predetermined specific period of timesuch that the valve 10 provides a predetermined quantity of fluid. Forexample, if a total volume of fluid flow through the valve 10 is desiredto be 1.6 gallons and the sensed static pressure is 60 psi, themicroprocessor 228 can actuate the solenoid 202 for a firstpredetermined period of time corresponding to a flow through the valve10 of 1.6 gallons. However, if the sensed static pressure is 50 psi, themicroprocessor 228 would actuate the solenoid 202 for a secondpredetermined period of time greater than the first predetermined periodof time in order to provide the same amount of water through the valve10.

In another aspect of the invention, the pressure transducer 216 can beadapted to monitor the dynamic fluid pressure during operation of thevalve to control the amount of water flow through valve 10. For example,the precise volume of fluid flow through valve 10 for a given period oftime can be calculated based on the interior volume of valve 10, thetime of flow through valve 10 and the fluid pressure of the waterflowing through valve 10. For a given fluid pressure, it can becalculated that the operating time for valve 10 may be a certain periodof time for a given flow volume. For example, it may be known based onnormal line pressure from the water source through inlet 18 that valve10 should remain open for a specified period of time (based on operationof solenoid 202), such as 3 seconds, to effect a specified flow volume,such as 1.6 gallons per flush. The line pressure from the water source,however, may fluctuate depending on a number of factors, such asmultiple fixtures attached to the water source operating simultaneously.By monitoring the dynamic fluid pressure within the valve 10 duringoperation of the valve, such as through the pressure transducer 216, theoperating time of the valve can be adjusted during operation of thevalve 10 so as to ensure that the desired flow volume is achievedthrough the valve 10.

For example, when the actuation signal is received from the actuator226, the microprocessor 228 can send signal the pressure transducer 216to sense the static pressure of the fluid within valve 10, such as inthe core tube 206. Based upon this sensed static pressure, an initialactuation time for the solenoid 202 to provide a predetermined volume ofwater through the valve 10 is determined. This initial actuation timefor solenoid 202 can be pre-calculated based upon the sensed pressurewhen applied with the known interior volume of valve 10 and the desiredamount of water flow therethrough. In this embodiment, the pressuretransducer 216 continues to monitor the dynamic fluid pressure in thecore tube 206 during valve actuation and operation. If this dynamicfluid pressure varies during the flushing cycle, the microprocessor 228adjusts the actuation time of the solenoid 202 in order to compensatefor fluid pressure variation, to ensure that the desired volume offlushing water is delivered through valve 10.

For example, a desired flow volume, such as 1.6 gallons per flush, isrequired when a normal flush request is received. Based upon the initialstatic pressure measurement, the microprocessor calculates the initialoperating time for solenoid 202 to ensure that valve 10 remains open forthe calculated operating time. For example, if based upon the initialstatic pressure measurement a flush time of 3 seconds is determined bythe microprocessor 228 to correspond to a desired total volume throughthe valve 10, such as 1.6 gallons per flush, the solenoid 202 isactuated for the determined time period. However, if during thisflushing process the dynamic fluid pressure sensed by the pressuretransducer 216 varies from a predetermined value or range, such as byincreasing or decreasing from the initial static pressure beyond apredetermined amount, the microprocessor 228 recalculates the amount oftime the solenoid 202 needs to be activated in order to maintain valve10 open for an appropriate time to ensure that the desired volume flowtherethrough is achieved, such as a discharge volume of 1.6 gallons fromthe valve 10. This ensures a desired amount of fluid is discharged fromthe valve 10 even if the fluid pressure varies during the operation ofthe valve 10 such as during the flushing process. That is, knowing theinitial pressure, the dynamic pressure, and the flow rate through thevalve 10 at the dynamic pressure, the microprocessor 228 can determinean actual flush time needed to flush a desired amount of water throughthe valve 10. In this manner, the effective flushing volume of valve 10will remain constant over the life of valve 10, regardless of wearing ofthe internal components of valve 10, which can alter the effectiveflushing volume of conventional diaphragm valves over time.

In the embodiment shown in FIG. 12, the pressure transducer control 230is located on the valve 10, such as on the solenoid 202. The pressuretransducer control 230 is connected to the main control board 218 in anyconventional manner, such as by a cable 234 having one or more wires.The pressure transducer 216 is connected to the pressure transducercontrol board 230 in any conventional manner, such as by cables or wires236. The control board 218 can provide electrical power to thetransducer control board 230 and/or solenoid 202, such as by a cable237, such that the relief function and flush function as described abovecan be maintained.

In the embodiment, shown in FIG. 13, the main control board 218, whichincludes the pressure transducer control 230 and associatedmicroprocessor 228 and amplifier 232, is located directly on the valve10, such as on the solenoid 202. A power source 240, such as aconventional wall outlet or a battery, is in electronic communicationwith the main control board 218 and/or solenoid 202 in conventionalmanner, such as by a cable 242. The actuator 226 is connected to themain control board 218 on the solenoid 202. The flushing and/or reliefactions occur in similar manner as described above.

In the electronic relief systems described above, electrical power canbe continually provided to the pressure transducer 216 such that thetransducer 216 continually monitors the fluid pressure within the valve10. However, in an alternate embodiment, electrical power may besupplied to the pressure transducer 216 to effect monitoring at aspecific time only, such as when the actuator 226 is activated. When theactuator 226 is activated, the microprocessor 228 sends power to thetransducer 216 to sense the static fluid pressure. Based upon thisstatic pressure, a flush time (i.e., solenoid activation time) iscalculated to achieve a desired flush volume. The transducer 216 canremain powered during the flush to monitor the dynamic fluid pressureand adjust the flush time as described above. Moreover, themicroprocessor 228 may be programmed to supply power to the pressuretransducer 216 at intermittent time periods, such as every 10 minutes,to intermittently monitor the internal pressure within valve 10.

It is further contemplated that the pressure monitoring function of thetransducer 216 may be utilized as a maintenance function for valve 10.For example, the internal components of diaphragm valves typically wearover time, which can result in prolonged fluid flow therethrough,wasting water. Oftentimes, such wearing causes the valve to take alonger period of time in order to reseal the diaphragm based upon thetime required to build up water pressure within the valve 10 at theinlet side of the diaphragm 26. The pressure transducer 216 may beprogrammed to detect the water pressure within valve 10 after a certainperiod of time after a normal flush as requested and effected. Thetypical range of time required to achieve the water pressure necessaryto effect resealing of diaphragm 26 and closure of the valve 10 is knownbased on normal operation of the valve 10. A comparison of the waterpressure after a normal flush at the known time period can provideinformation regarding the wear of the valve. For example, if the waterpressure detected after the predetermined time period is lower than thetypical water pressure value as known, valve 10 may require servicing orreplacement. A signal including this information could be transmitted toa central processing unit, which could then alert the maintenance staffthat servicing is required.

It will be readily appreciated by those skilled in the art thatmodifications may be made to the invention without departing from theconcepts disclosed in the foregoing description. For example, variouscomponents of the mechanical and electronic relief devices describedabove can be used together in the same valve. Accordingly, theparticular embodiments described in detail herein are illustrative onlyand are not limiting to the scope of the invention, which is to be giventhe full breadth of the appended claims and any and all equivalentsthereof.

What is claimed is:
 1. A system for detecting wear in a flush valve, thesystem comprising: (a) at least one pressure sensor adapted to measure awater pressure within the flush valve; (b) at least one microprocessorin communication with the at least one pressure sensor, the at least onemicroprocessor configured to: (i) determine the water pressure withinthe flush valve measured by the at least one pressure sensor at or aftera predetermined time following operation of the flush valve, thepredetermined time equal to or exceeding a known time required to resealthe flush valve during normal operation, wherein the operation of theflush valve comprises opening of the flush valve; (ii) compare thedetermined water pressure with a pressure value sufficient to reseal theflush valve during normal operation; and (iii) determine if the flushvalve is taking a different period of time to reseal than the flushvalve during normal operation based at least partially on thecomparison.
 2. The system of claim 1, further comprising the flushvalve, the flush valve comprising a vent system adapted to vent waterfrom a fluid inlet to a fluid outlet, thereby establishing a pressuredifferential across a portion of a valve element and causing operationof the flush valve, wherein the determined water pressure is a pressuremeasured within the vent system.
 3. The system of claim 2, wherein thepressure value sufficient to reseal the flush valve when the valve isoperating normally comprises a typical water pressure present in thevent of the flush valve after the predetermined time after operation ofthe flush valve.
 4. The system of claim 1, wherein the flush valvecomprises a diaphragm, and wherein the diaphragm reseals the flushvalve.
 5. The system of claim 1, wherein the pressure value sufficientto reseal the flush valve during normal operation is an average pressurevalue of previous pressures detected in the flush valve.
 6. The systemof claim 1, wherein the pressure value sufficient to reseal the flushvalve during normal operation is based at least partially on at leastone other pressure detected in at least one other flush valve.
 7. Thesystem of claim 1, wherein the determination that the flush valve isworn is based at least partially on a differential between thedetermined water pressure and the pressure value sufficient to resealthe flush valve, such that the flush valve is determined to requireservicing or replacement when the detected water pressure is less thanthe pressure value sufficient to reseal the flush valve.
 8. The systemof claim 1, wherein the at least one microprocessor is furtherconfigured to transmit at least one signal to at least one centralprocessing unit, the at least one signal indicating that the flush valverequires at least one of service and replacement.
 9. The system of claim8, further comprising the at least one central processing unit, the atleast one central processing unit configured to receive the at least onesignal from the at least one microprocessor.
 10. The system of claim 8,wherein the at least one signal comprises an alert.
 11. An apparatus fordetecting wear in a flush valve, the flush valve configured to at leastpartially reseal after operation based at least in part upon waterpressure within the flush valve, the apparatus comprising at least oneprocessor configured to: determine a measured water pressure in at leasta portion of the flush valve at or after a predetermined time followingoperation of the flush valve, wherein the operation of the flush valvecomprises opening of the flush valve; compare the measured waterpressure with a comparison water pressure; determine if the flush valveis taking a different period of time to reseal than the flush valveafter opening during normal operation based at least in part on thecomparison; and generate at least one signal or alert that the flushvalve is determined to require service or replacement if the flush valveis taking a different period of time to reseal than the flush valveafter opening during normal operation.
 12. The apparatus of claim 11,wherein the comparison water pressure comprises a typical water pressureor pressure range required to at least partially reseal the flush valveduring normal operation, and wherein, during normal operation, thetypical water pressure or pressure range is present in the flush valveat or after the predetermined time.
 13. The apparatus of claim 11,wherein determining the measured water pressure comprises receiving,from at least one pressure transducer, the measured water pressure ordata representing the measured water pressure.
 14. The apparatus ofclaim 11, wherein the comparison water pressure comprises at least oneprevious water pressure measured within the flush valve.
 15. Theapparatus of claim 11, wherein the comparison water pressure comprisesan average of previous water pressures measured within the flush valve.16. The apparatus of claim 11, wherein the comparison water pressurecomprises at least one water pressure measured within at least onedifferent flush valve.
 17. The apparatus of claim 11, wherein the atleast one processor is further configured to transmit the at least onesignal or alert to at least one of a central processing unit and aremote device.
 18. A method for detecting wear in a flush valve, theflush valve configured to at least partially reseal after operationbased at least in part upon water pressure within the flush valve, themethod comprising: measuring a water pressure in at least a portion ofthe flush valve at or after a predetermined time following operation ofthe flush valve, wherein the operation of the flush valve comprisesopening of the flush valve; comparing, with at least one processor, themeasured water pressure with a comparison water pressure to determine adifference in pressure; determining, with at least one processor, if theflush valve is taking a different period of time to reseal than theflush valve after opening during normal operation based at leastpartially on the difference in pressure; and generating, with at leastone processor, at least one signal or alert if the flush valve isdetermined to be worn, wherein the comparison water pressure comprises atypical water pressure or pressure range required to at least partiallyreseal the flush valve during normal operation, and wherein, duringnormal operation, the typical water pressure or pressure range ispresent in the flush valve at or after the predetermined time.
 19. Themethod of claim 18, wherein the typical water pressure or pressure rangerequired to at least partially reseal the flush valve during normaloperation is determined based on at least one of the following: aprevious water pressure measured within the flush valve, an average ofprevious water pressures measured within the flush valve, at least onewater pressure from at least one other flush valve, or any combinationthereof.